JERES-N-150 Erosion Resistant Refractory Lining-FCC Piping

$Page 1: JERES-N-150 Erosion Resistant Refractory Lining-FCC Piping$
JERES-N-150 Erosion Resistant Refractory

Linings in FCC Piping and Vessels

Revision 0

Responsibility JER Engineering

29 April 2008

Jubail Export Refinery Engineering Standards


JERES-N-150 Rev. 0

Erosion Resistant Refractory Linings in FCC Piping and Vessels 29 April 2008

This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by

any means without prior approval by the Company.

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Revision Tracking

Revision Revision Date Scope of Revision

0 29 April 2008 Issued for bid package

00 31 March 2008 Issued for bid package only for review


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Table of Contents

Section Contents Page

1 Scope 5

2 Conflicts, Deviations and Clarifications 5

3 References 9

4 Definitions 9

5 Refractory Materials 10

6 Anchorage 11

7 Fibres 12

8 Welding of Anchorage 13

9 Refractory Application 15

10 Heat-Curing 23

11 Sampling, Qualification and Testing 24

12 Inspection / Repairs 29

13 Summary of Approvals / Documentation 31

Appendixes

Annex 1 Vee Anchor for Gunned/Cast Monolithic Linings 33

Annex 2 Vee Anchor for Gunned/Cast Monolithic Linings 34

Annex 3 Two-Piece Wye Anchor for Gunned/Cast Dual-Layer 35


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Annex 4 Dual-Layer Lining Stud and Plate-Head System 36

Annex 5 S Bar Anchorage 37

Annex 6 Hexmesh Weld Pattern 38

Annex 7 Hexmesh Weld Pattern 39

Annex 8 Hexmesh Parallel Joint Details 40

Annex 9 Hexmesh Re-Sizing of Small Hexagons 41

Annex 10 Hexmesh Conical Joint Details 42

Annex 11 Hexmesh Joints – Corrective Details 43

Annex 12 Flexmesh 44

Annex 13 Corner Tabs 45

Annex 14 Male/Female Backing Ring System 46

Annex 15 Joint Detail for Radiographed Weld Seams 47

Annex 16 Hot-Wall to Cold-Wall Transition 48

Annex 17 Table 1 – Refractory Material Properties 49

Annex 18 Summarising of Ex-Total, Ex-Fina and Ex-Elf Specifications 53


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1 Scope

1.1 This Specification details the application guidelines for the installation of insulating and erosion resistant refractory linings of vessels, internals and transfer lines in Fluid Catalytic Cracking Units (FCCU).

It defines the type of anchorage, selection of refractory materials, types of application and sampling, testing and inspection requirements.

1.2 An oblique (♦) indicates that a decision/approval is required by the Owner/Purchaser.

2 Conflicts, Deviations and Clarifications

2.1 Any conflicts between this standard and other applicable Company Engineering Standards (JERES), Material Specifications (JERMS), Standard Drawings (JERSD), Engineering Procedures (JEREP), Company Forms or Industry standards, specifications, Codes and forms shall be brought to the attention of Company Representative by the Contractor for resolution.

Until the resolution is officially made by the Company Representative, the most stringent requirement shall govern.

2.2 Where a licensor specification is more stringent than those of this standard, the Licensor’s specific requirement shall apply.

2.3 Where applicable Codes or Standards are not called by this standard or its requirements are not clear, it shall be brought to attention of Company Representative by Contractor for resolution.

2.4 Direct all requests for deviations or clarifications in writing to the Company or its Representative who shall follow internal Company procedure and provide final resolution.

3 References

The selection of material and equipment, and the design, construction, maintenance, and repair of equipment and facilities covered by this standard shall comply with the latest edition of the references listed below as of the CUT-OFF DATE as specified in the Contract unless otherwise noted.


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3.1 ASTM Standards

A 167 Stainless and Heat-Resisting Chromium-Nickel Steel Plate, Sheet and Strip.

A 176 Stainless and Heat-Resisting Chromium Steel Plate, Sheet and Strip.

A 240 Heat-Resisting Chromium and Chromium-Nickel Stainless Steel Plate, Sheet and Strip for Fusion Welded Unfired Pressure Vessels.

A 368 Stainless and Heat-Resisting Steel Wire Strand.

A 479 Stainless and Heat-Resisting Steel Bars and Shapes for use in Boilers and other Pressure Vessels.

A 580 Stainless and Heat-Resisting Steel Wire.

A 743 Corrosion-Resistant Iron-Chromium, Iron Chromium Nickel and Nickel-Base Alloy Castings for General Application.

A 744 Corrosion – Resistant Iron – Chrome – Nickel Based Alloy Casting for Severe Service.

A 820 Standard Specification for Steel Fibres for Fibre Reinforced Concrete.

C 71 Definitions of Terms Relating to Refractories

C 93 Cold Crushing Strength and Modulus Rupture of Insulating Firebrick.

C 109 Compression Strength of Hydraulic Cement Mortars (Using 2 inch/50mm Cube Specimens).

C 113 Test method for reheat Change of Refractory Brick

C 133 Cold Crushing Strength and Modulus of Rupture of Refractory Brick and shapes.

C 134 Size and Bulk Density of Refractory Brick and Insulating Firebrick

C 201 Thermal Conductivity of Refractories.

C 417 Thermal Conductivity of Unfired Monolithic Refractories.

C 577 Permeability of Refractories.


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C 583 Modulus of Rupture of Refractory Materials at Elevated Temperatures.

C 704 Abrasion Resistance of Refractory Materials.

C 865 Firing Refractory Concrete Specimens.

C 1113 Standard Test Method for Thermal Conductivity of Refractories by Hot Wire.

3.2 ISO Standards

ISO 1109 Refractory products – Classification of dense shaped

ISO 10081-1 Basic refractory products – Classification Part 1: products containing less than 7% residual carbon

ISO 10059-1 Dense, shaped refractory products – Determination of cold compressive strength – Part 1: referee test without packing

ISO 8895 Shaped insulating refractory products – Determination of cold crushing strength

ISO 5014 Refractory products – Determination of modulus of rupture at ambient temperature

ISO 5016 Shaped insulating refractory products – Determination of bulk density and true porosity

ISO 8894-1 Refractory materials – Determination of thermal conductivity – Part 1: hot wire method (cross-array)

ISO 8894-2 Refractory materials – Determination of thermal conductivity – Part 2: hot wire method (parallel)

ISO 2477 Shaped insulating refractory products – Determination of permanent change in dimensions on heating

ISO 2478 Dense, shaped refractory products – Determination of permanent change in dimensions on heating

3.3 Order of preference

The refractory materials and linings referred to in this specification must satisfy, in order of preference, the following:

− any particular job or design specification (when applicable)

− this specification (SG ISL 230)


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− those standards and specifications referred to in this specification (SG ISL 230)

− refractory manufacturer’s recommended installation instructions and dry-out

3.4 Documentation to be submitted to the Owner/Purchaser

The Applicator shall submit the Manufacturers installation instructions and documentation to the Owner/Purchaser for approval. This documentation should contain the following information:

3.4.1 Physical properties guaranteed by the Manufacturer

− Cold Crushing Strength in accordance with ASTM C109 or C133.

− Modulus of rupture in accordance with ASTM C133 or C583.

− Permanent Linear Change (PLC) and Return Thermal Expansion (RTE).

− Erosion loss (not required for insulating castables) in accordance with ASTM C704.

− Thermal Conductivity values for the intended service temperature in accordance with ASTM C201 and C417 or C1113.

− Bulk Density after drying to 110 °C.

− Return Thermal Expansion expressed in millimetres per linear metre (540-815°C)

− Percentage of water to be used for mixing and installation.

− Volumetric yield (without losses).

− Type of binder, aggregates and maximum grain size.

− Type of packaging for shipment.

− Requirements for storage and expected shelf-life.

− Maximum long-term service temperature (°C).

− Chemical composition (confirm if Rapid Fire Technology RFT fibres are used)

3.4.2 Application of the refractory materials

The Installer shall submit the following information to the Owner/Purchaser for approval:

− Experience and reference list.


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− List of skilled/qualified operatives with applicable certified documentation.

− Detailed installation procedures indicating the following:

• Application procedure

• Type of formwork

• Maximum age of products prior to their usage

• List of all equipment to be employed indicating type, make and capacities

• Mixing procedure

• Sampling and testing to be performed, including an identification / traceability map showing the type of material, batch number, sample number and location in each lined section

• Operator qualification panels to be performed

• Repair procedures

• Method of curing

• Typical quality control data sheets

• Method of dry-out, equipment to be used and dry-out curve.

4 Definitions

4.1 Definitions presented in this Standard and other JER documents have precedence over other definitions. Conflicts between various definitions shall be brought to the attention of Company Representative by the Contractor for resolution.

Company: Jubail Export Refinery.

Company Representative: A designated person from the Company or an assigned third party representative.

Company Inspector: A designated person or an agency responsible for conducting inspection activities on behalf of the Company.

4.2 List of Definitions

Owner

TOTALFINAELF or its associates, affiliates or subsidiaries.


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Purchaser

The Owner or its appointed engineering/procurement contractor.

Vendor

The Company or Body selling the design and/or process license of the equipment to be refractory lined.

Fabricator

The Company or Body physically fabricating the equipment to be refractory lined.

Installer

The Company or Body performing the refractory installation.

Manufacturer

The Company or Body manufacturing the refractory material.

Inspector

The Company or Body performing the inspection of the anchorage/refractory lining on behalf of the Owner. The Inspector could also be the Owner or the Purchaser.

4 Scope of Supply

The scope of supply will be as defined in the purchase order.

The Owner, the Purchaser or the Vendor, will furnish the drawings and documentation necessary to provide the scope of supply unless otherwise stated in the purchase order. All drawing and documentation will be approved for construction by the Owner or Purchaser.

The Installer will generally also supply the refractory materials to be used in the lining of the proposed equipment. In some cases the refractory materials may be provided by the Owner, Purchaser, Vendor or Fabricator as ‘free-issue’ for use by the Installer.

In some cases, the Installer may be required to supply and/or install the anchorage.


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5 Refractory Materials

The Installer shall submit typical data sheets as per § 2.4.1 and pre-shipment test results as per § 11.1 for Owner approval prior to any refractory being installed.

Each pallet of material shall be clearly identified with:

− Type of material

− Batch number

− Date of manufacture (if not included in batch number)

Additionally, each bag of refractory material shall be identified with material type and batch number to ensure traceability if bags are removed from the pallet.

All materials shall be uniformly pre-mixed and pre-packed at the Manufacturers’ plant. Metallic fibres, when required, will be added at the job site unless otherwise specified.

Refractory materials shall be used within 4 months of initial pre-shipment testing or within 3 months of each succeeding satisfactory re-qualification test. However, material older than 12 months shall not be used.

Materials, which exhibit agglomeration or hard lumps, shall be discarded.

Materials shall be stored in a dry, well-ventilated area and never in direct contact with the ground. The temperature during storage must be maintained between 5°C – 35°C. If storage in a covered, fixed or temporary building is not possible, then the pallets of material shall be suitably covered with plastic sheeting or tarpaulins to protect against rain. In hot weather, adequate ventilation shall be provided to avoid build up of humidity within shrink-wrapped pallets.

Refractory materials are classified into the following types:

− Type 1 - Heat-insulating

− Type 2A - Medium Erosion resistant / heat-insulating

− Type 2B - Less Erosion resistant / more heat-insulating

− Type 3A - Extreme erosion resistant

− Type 3B - Ultra erosion resistant


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The recommended manufacturers of each product and a range of data values are given in Annex 17, Table 1.

Proposals to use other materials than those specified, shall be submitted to the Owner for approval.

6 Anchorage

6.1 Vee anchors

Vee anchors shall be made of 6-8mm diameter wire as per Annex 1.

Material shall be stainless steel 304H 18-8 unless otherwise specified.

The use of anchors as per Annex 2 shall be specified by, or require approval from the Owner.

6.2 Hexagonal Mesh

Hexagonal mesh shall be made from strips of 2mm thickness and 19 or 25mm deep as specified with off-set bonding holes and lances as per Annex 7, figure 7e.

Strips shall be tightly clinched with double tabs such that the adjoining strips do not separate more than 0.5mm during forming and installation. The mesh shall be resistant to bending and be sufficiently rigid so that it does not flex between points of attachment to the shell.

The hexagonal mesh shall measure approximately 50mm between parallel sides. Two tabs measuring 6mm wide x 12mm long shall protrude into each hexagon.

Where specified, edge bars used to terminate the refractory lining will be 5/6mm thick and of the same material type as the hexagonal mesh. Hexagonal mesh will either be Type 304H or 405/410S depending on the service of the components to be lined (304H on austenitic components, 405 / 410 S on ferritic components)

In small diameter piping (less than 400mm ID) or when specified, S-bars, small vee anchors or flexmesh shall be used. Flexmesh shall be made from strips of 2mm thickness and 16 or 19mm deep as specified. The strips shall be joined together using a 3mm diameter continuous pin, which shall be bent at right angles at each end to maintain the flexmesh closely bound – see Annex 12.

6.3 S-bars


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S-bars will be made from 2mm thick strips in type 304H unless otherwise specified. See Annex 5.

S-bars are generally used for thin wall (19-25mm thick) erosion resistant linings and/or in areas of tight curvature, but in some cases will also be used in dual layer linings or 100 – 125mm thick insulating linings as specified by the Owner.

6.4 Dual layer linings

Dual layer linings will be anchored using wye-anchors (vee anchors secured to a 10mm rod) as per Annex 3 or hexagonal mesh welded to plate-heads as per Annex 4. Plate-heads shall be made of 6mm thick x 50 x 50mm plate screwed onto a 10mm diameter stud – all in type 304H unless otherwise specified. Where specified, S-bars secured to a 10mm diameter stud may also be used.

The length of the stud and anchorage for the hot-face refractory will be specified by the Owner depending on the location and service of the dual layer lining.

Additional vee anchors may be required when applying the back-up lining, particularly in overhead positions.

7 Fibres

7.1 Where specified, fibre reinforcement will be added to refractory material at a ratio of 2% by weight.

7.2 For cast refractory cold drawn fibres shall be used measuring 25mm long by 0.3 – 0.35mm diameter with chemical requirements per ASTM A580.

7.3 For gunned refractory melt extract fibres shall be used measuring 25mm long by 0.3 – 0.42mm with chemical requirements per ASTM A743/A743M.

7.4 Dramix fibres (with hooked ends) may be used for both cast or gunned operations but added at no more than 1% by weight.

7.5 All fibres shall be added to refractory castables prior to water addition via a sieve with approximately 15mm openings to avoid ‘balling’ during mixing and ensuring even distribution.

8 Welding of Anchorage

8.1 Surface preparation


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Prior to welding of any anchorage and installation of refractory, the shell must be cleaned of loose rust, oil, grease, scale and any other foreign matter by sand-blasting to SA-2 standard. Sandblasting will not normally be required for austenitic stainless steel surfaces but can be cleaned by steam to remove grease, oil etc. In coked areas, it may be necessary to use chipping hammers and / or needle guns and / or grinding to achieve this.

When the parent metal is not stainless steel, sandblasting of the shell prior to hexagonal mesh anchorage installation is mandatory.

If further oxidation occurs between initial cleaning of the shell and refractory installation, the shell and the anchorage will require re-cleaning.

In the case of vee anchors or stud attachment, welding of such can be performed after localised spot grinding of the shell in the area of each anchor and then sandblasting can occur after all anchorage has been installed but immediately prior to refractory installation.

Proposals for alternate methods of cleaning shall be submitted to the Owner for approval.

When plastic caps are specified, these shall be installed after sand-blasting.

8.2 Welding of vee anchors

Welding of vee anchors shall be as per Annex 1 or 2, anchors to be randomly orientated and on an off-set pitch from row to row.

Additional anchors will normally be required local to or at pipe intersections, corners, nozzles, openings and manways.

Wax crayons shall not be used to locate anchor positions. Welding of anchors on weld seams is prohibited.

All welding shall be done after any radiographing requirements, but before any applicable post-weld heat-treatment requirements. All weld slag shall be removed prior to refractory installation.

Anchors are not required if the final lining ID is less than 500mm and the refractory thickness is at least 75mm.

8.3 Welding of hexagonal mesh


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8.3.1 Hexmesh welded directly to the shell shall be in accordance with Annex 6. The hexmesh will be installed with the strips perpendicular to the direction of the process flow where possible.

8.3.2 Alternate weld patterns are shown in Annex 7 and are only to be used when specified or approved by the Owner.

8.3.3 As a general rule, no hexagonal opening shall be less than 0.5 times or greater than 1.5 times the original cell size. In order to respect this rule, small sections of cut hexmesh strips (bridging pieces) will have to be installed or sections of a hexagon removed.

Details of acceptable typical panel joints and methods of attaching hexmesh to edge-bars are shown in Annex 6, 8, 9, 10 + 11. Bridging pieces shall be the same depth, thickness and material type as hexmesh.

Joints between panel sections shall be off-set to avoid continuous seams in the direction of process flow.

8.3.4 When attaching panel ends to adjoining panels, edge-bars or adjoining hexmesh strips, weld full depth – welding on the top surface of the hexmesh is prohibited.

8.3.5 Weld spatter, high spots or misaligned sections of hexmesh will be ground flush to facilitate smooth surface finishing of the refractory.

8.3.6 Maximum gap between hexmesh strips shall be 0.5mm.

8.3.7 Edge-bars shall be used to terminate the lining to avoid leaving open-ended hexes.

8.3.8 At points of lining transition such as pipe intersections, corners, manways, openings etc., special variable angled/fixed corner tabs or U-tabs will be installed as per Annex 13.

8.3.9 Hexmesh panel joints on suspended dual-layer lining systems will be connected using a 2mm thk binding strip with bonding holes as per Annex 10.

Welding of plate-head studs and attachment of hexmesh to plate-heads will be as per Annex 4.

Unless otherwise specified, welding of hexmesh to plate-heads will be performed after application of the back-up lining.


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8.3.10 Flexmesh shall be welded in accordance with Annex 12 and the guidelines given in § 8.3.3 thru 8.3.7 above will apply.

8.4 Welding of alternative anchorage

♦ Welding of dual-layer wye anchors will be in accordance with Annex 3. The length of the stud, the anchorage for the hot-face refractory and the spacing will be specified by the Owner depending on the location and service of the dual layer lining.

Welding of S-bars will be in accordance with Annex 5.

9 Refractory Application

9.1 General requirements (For all refractory types)

Prior to refractory application, all anchorage shall be checked by :

− hammer / bend test,

− visual / dimensional check for pitch, location, size, etc. …

− random PMI test.

Refractory installation shall not begin until after completion of all welding, post-weld heat-treatment and pressure testing (pneumatic or hydraulic).

♦ Proposals to install refractory prior to pressure testing, shall be submitted to the Owner for approval.

The steel surface to be lined shall meet the preparation requirements of § 8.1. Remove all loose debris by vacuuming.

Water for mixing shall be clean and free of foreign debris and impurities and suitable for drinking (potable), with a pH content of 6-8 and less than 50ppm chlorides. Water temperature shall be between 4°C and 26°C.

The refractory lining and the surface to which it is being applied shall be maintained at a temperature above 10°C (5°C for type 3 materials) during application, air-curing and until the lining is heat-cured.

To maintain this temperature, it may be necessary to employ heating within the vessel and / or external insulation. Live steam shall not be used for this purpose.


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In hot weather, the refractory lining and the surface to which it is being applied shall not exceed 30°C. Prior to and during application, it may be necessary to provide shading on the external of the vessel and / or cooling by water spraying.

When specified, metallic fibres shall be added to the refractory after thorough dry-mixing via a sieve as per § 7.5.

After addition of the fibres, water for pre-dampening of the material shall be added as per the manufacturer’s instructions and allowed to mix for the specified time.

The full contents of each bag of premixed refractory shall be used. Do not use damaged, wet or lumpy materials.

Refractory materials from one manufacturer and / or trade name shall not be mixed with other manufacturers and / or trade names.

The use of additives of any kind is not permitted.

Lined sections shall not be moved until after the lining has taken its initial set (see manufacturer’s recommendations).

9.2 Pneumatic Gunite (Heat-insulating refractory Type 1 + Types 2a/2b)

9.2.1 Application of Type 1 refractory shall be made by the pneumatic gunite method unless otherwise specified or approved by the Owner.

9.2.2 Structural supports, nozzles or other items within the lining thickness shall be wrapped with ceramic fibre paper as per the following table:

OD of pipe

(mm) Thickness of fibre

(mm) Up to 250 1.5 251-400 3 401-750 6 Over 750 See specific design

This paper shall be glued in place and wrapped with plastic tape or similar to prevent water absorption during application of the refractory.

Where specified, ceramic fibre blanket (13-25mm thick) shall be of 128 kg/m3 density.


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When specifically detailed on drawings, annular voids or spaces around nozzles / sleeves, shall be filled with bulk ceramic fibre.

9.2.3 Openings shall be temporarily sealed by means of wooden, steel or polystyrene plugs of such dimensions that they fit snugly into the openings and prevent ingression of refractory material during application.

They shall be made with a taper and coated with oil or grease to facilitate removal. Removal shall be performed as and when the lining has air-cured and completely hardened.

9.2.4 Mixing shall be performed in paddle mixers – the use of cement mixers is not acceptable.

During operator qualification (§ 11.2.1), the mixers will have demonstrated their ability to homogeneously mix the refractory material without any build-up or balling of material to the paddles or the corners / sides of the mixer.

9.2.5 The Applicator will record the batch numbers of material, relevant water addition and ambient conditions.

9.2.6 Only qualified personnel familiar and experienced in pneumatic gunite application shall be allowed to perform this work.

Operator qualification tests as par § 11.2.1 will have to be performed prior to any work taking place.

9.2.7 Compressed air and water shall be supplied to the gun nozzle at a suitable, steady, un-fluctuating pressure as determined during the pre-qualification tests so as to ensure minimum rebound loss, homogeneous mixing and little or no surging.

9.2.8 Ideally, the equipment to be lined shall be in a vertical position whereby allowing gunite to be performed by applying horizontal, circumferential bands – always commencing the first band at the bottom of the vessel and working upwards.

Gunning down-hand below an angle of 45° is prohibited due to probable rebound entrapment.

If equipment to be lined cannot be placed in the vertical position, the bottom 90° shall be applied by hand-casting ensuring that the longitudinal construction joints are not continuous and in line with process flow gas.


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9.2.9 Circumferential bands should be commenced using a wooden shot-board or similar to define the extent, form and thickness of the lining at the start point and top of the band. When commencing a new vessel, a shot-board may also be required at the bottom of the first band.

Where possible, each band should be applied continuously and without interruption.

If an interruption does occur, then the lining edges will be left cut straight and perpendicular to the shell, or preferably dove-tailed. Before continuing, the edges of applied refractory shall be cleaned of any loose debris or rebound and thoroughly wetted.

Longitudinal joints shall be staggered.

9.2.10 Within each band, the lining shall be applied in vertical columns, building up to full thickness in a monolithic application by using a circular motion of the nozzle – also avoiding rebound entrapment. A wide-angle ‘painting’ technique is prohibited.

9.2.11 Care should be taken to avoid accumulation of rebound or over-spraying of material on the surface of previously lined sections or on the vessel wall/anchors yet to be lined.

9.2.12. Surface finishing of a completed area shall be performed while the material is still soft with a scraping action using a long wooden or aluminium rule pulled across the surface of the refractory and the shot-boards and then scraped with the side of a trowel leaving a rough surface finish. Floating or smoothing of the surface is prohibited.

9.2.13 Completed gunned linings shall have a thickness tolerance of –0mm, +12mm.

9.2.14 The Applicator will prepare the necessary as-installed test samples as per the requirement of § 11.3.1 and record the location and mixing data of such.

9.2.15 After application, the lining shall be allowed to cure for 24 hours. As the refractory begins its initial set, the lining should be sprayed with a fine water mist at regular intervals to avoid rapid de-hydration. Some materials exhibit an exothermic reaction during initial hydration, particularly in hot climates and spraying may be required on an on-going basis.

Care should be taken not to direct power jets directly onto the surface of the refractory which may damage or wash out the cement content.


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As an alternative, an organic curing membrane compliant with ASTM C309 containing a coloured dye may be used which shall also be applied by spraying. This option should not be used in hot climates.

9.3 Handpacking / ramming (Erosion resistant refractory Types 3A/3B)

Proposals to install Types 3A/3B erosion resistant material by other methods of application shall be submitted to the Owner for approval.

Only qualified personnel familiar and experienced in hand-packing of erosion resistant materials shall be allowed to perform this work.

Operator qualification tests as par § 11.2.3 will have to be performed prior to any work taking place.

The amount of liquid additive (water or special binder) shall have been pre-determined by the ‘pre-shipment’ manufacturers test results, and, should be used initially as the starting percentage to be added to mix.

Variations on water addition may be made as long as the manufacturers maximum amount is not exceeded.

Addition of extra liquid in ‘special binder’ format is not permitted.

The mixing of refractory should be performed in a planetary type mixer, e.g. Hobart or similar. Mixing times will vary due to climatic and product variations, but generally will be approximately 3-5 minutes from addition of liquid, or until the mixture can be seen to be ‘folding’ around the mixing bowl in 3 to 4 separate pieces.

Note: Addition of fibres (if required) should be added at the dry mixing stage by means of a sieve to avoid ‘balling’ of fibres.

Mix only as much erosion resistant lining that can be used within 15 minutes after the addition of water unless otherwise specified by the Manufacturer.

Do not use any lining material that has taken an initial set.

Mixer bowl, paddle and working tools shall be periodically washed to remove build-up of lining material and thoroughly dried prior to re-use.

After mixing, the material should be ‘thumbed’ into the anchorage ensuring all voids are completely filled.


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A secondary ‘packing’ action should then be performed by either the use of a rubber mallet or pneumatic rammer to ensure complete compaction of material.

Excess material should be cut level with the surface of the anchorage and rubbed over with a hard wood block or similar to obtain a smooth surface.

Care shall be taken not to leave the cells under/over filled and ensure that the refractory is tight to all sides of anchorage.

‘Wetting’ of wooden blocks or tools, or the refractory lining is not permitted to obtain a smooth finish.

Material that has taken the initial set phase should not be installed into the anchorage and should be discarded.

Individual hexagons must not be left part-filled and when an interruption to the lining occurs, all new surfaces to be lined shall be removed of set material and debris.

The erosion resistant lining tolerance thickness shall be –0.0 to +1.0mm.

The Applicator will record the batch numbers of material, relevant water addition and ambient conditions. The Applicator will also prepare the necessary as-installed test samples as per the requirement of § 11.3.3 and record the location, name of operative and mixing data of such.

9.4 Vibrocasting (Heat-insulating refractory Types 2A/2B)

Only qualified personnel familiar and experienced in vibrocasting materials shall be allowed to perform this work.

Operator qualification tests as par § 11.2.2. will have to be performed prior to any work taking place.

Structural supports, nozzles or other items within the lining thickness shall be wrapped with ceramic fibre paper 3mm thick unless otherwise specified.

This paper shall be glued in place and wrapped with plastic tape or similar to prevent water absorption during application of the refractory.

Where specified, ceramic fibre blanket (13-25mm thick) shall be of 128 kg/m3 density.


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When specifically detailed on drawings, annular voids or spaces around nozzles / sleeves, shall be filled with bulk ceramic fibre.

Openings shall be temporarily sealed by means of wooden, steel or polystyrene plugs of such dimensions that they fit snugly into the openings and prevent ingression of refractory material during application.

They shall be made with a taper and coated with oil or grease to facilitate removal.

Removal shall be performed as and when the lining has air-cured and completely hardened.

Watertight forms shall be used, suitably reinforced to maintain the profile and contour of the lining and be resistant to collapse from the force of the mass of refractory being cast.

Steel, wood, heavy-duty plastic or fibre-glass are considered suitable materials for such.

Forms shall be fabricated in several sections circumferentially, with at least one section having ‘keyed’ flanges whereby facilitating easy removal without damage to the installed lining.

Forms shall be suitably coated prior to their insertion into the equipment to be lined with a release agent (oil, grease or similar).

For irregular shaped or curved equipment, high-density polystyrene (Styrofoam) is considered acceptable with a minimum density of 32 kg/m3. This type of formshould be externally faced with a smooth, impermeable covering in order to achieve a regular surface finish on the lining.

Forms shall have suitable centring devices to maintain the specified lining thickness and concentricity/internal diameter of the lining.

Additionally, forms must be securely fastened to prevent movement or ‘floating’ during casting.

In some cases, it may be necessary to weld spacing or tie-bars to the equipment shell to act as form guides.

Proposals to use such shall be submitted to the Owner for approval.


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Sufficient electric or pneumatic vibrators capable of moving the total refractory mass shall be mounted externally on the equipment to be lined by means of steel pads, collars, chains or strops.

Welding of vibrators directly onto the shell is prohibited.

In certain cases it will be necessary to provide additional vibrators mounted internally on the forms themselves.

Vibrators shall not be used in the refractory material.

Mixing shall be performed in paddle mixers – the use of cement mixers is not acceptable.

During operator qualification (§ 11.2.2), the mixers will have demonstrated their ability to homogeneously mix the refractory material without any build-up or balling of material to the paddles or the corners / sides of the mixer.

The amount of water to be added shall have been pre-determined by the ‘pre-shipment’ manufacturers test results, and, should be used initially as the starting percentage to be added to the mix.

Variations on water addition may be made as long as the manufacturers maximum amount is not exceeded.

Vibrocasting shall be performed with the equipment in the vertical position and in a continuous pour – when casting elbows provision should be made to turn the vessel during the casting in order to achieve a continuous pour. The use of a pivoting jig structure or craneage may be necessary for this purpose.

The maximum ‘drop’ of material during casting shall not exceed 3500mm – when longer sections of pipe are to be cast, the forms should be fabricated with pouring ‘windows’ which are to be sealed off as the level of the cast rises.

Vibration shall be sufficient to eliminate voids and dry-fill spaces but not excessive whereby causing air bubbles or ‘rolling’ of the refractory material.

The Applicator will prepare the necessary as-installed test samples as per the requirement of § 11.3.2 and record the location and mixing data of such.

9.5 Freeflow castables


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When Freeflow castables are to be used, the requirements of § 9.4 above will be met with the exception of reference to mechanical vibrators.

10 Heat-Curing

10.1 Unless otherwise specified, all lined equipment will be dried out prior to transportation to site.

10.2 Dry-out will be performed using internal gas and thermocouples shall register the temperature throughout the lined area during the dry-out, including gas inlet, outlet and shell/skin temperatures.

Proposals to use alternative heating methods/equipment such shall be submitted to the Owner for approval.

10.3 The parameters of dry-out for new/repaired linings shall be as follows:

− Initial gas temperature to be between 50-100°C

− Raise temperature to 200°C at a maximum rate of 30°C per hour.

− Hold all sections of lining at 200°C for a minimum of 1.5 hours per each 25mm thickness

− Increase gas temperature at a maximum rate of 30°C per hour to 530°C

− Hold at 530°C for a minimum of 1.5 hours per each 25mm thickness

− Cool at a maximum rate of 80°C per hour

Proposals to use alternative dry-out curves such shall be submitted to the Owner for approval.

If the requirements of § 10.3 cannot be met, the lining shall be considered dry when the external shell temperature has been held at a minimum of 120°C for 8 hours.

NOTE: ‘Cold-wall’ vessels lined with types 1, 2A or 2B materials shall not be placed in a furnace but dried out using internal gas combustion as per § 10.2 above.

10.5 When external insulation is used to promote the dry-out, the metal temperature shall not exceed 200°C.

10.6 For type 3 materials, the equipment shall be heat-soaked in a furnace or by internal gas combustion as follows:


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− Initial gas temperature to be between 50-100°C

− Raise temperature to 200°C at a maximum rate of 30°C per hour.

− Hold all sections of lining at 200°C for a minimum of 2 hours

− Increase gas temperature at a maximum rate of 30°C per hour to 370°C

− Hold at 370°C for a minimum of 2 hours

− Cool at a maximum rate of 80°C per hour.

11 Sampling, Qualification and Testing

11.1 Preshipment testing

Prior to delivery of refractory materials from the Manufacturer’s plant, pre-shipment testing shall be performed as follows:

REFRACTORY

TYPE TEST SPECIMENS

PER SAMPLE SAMPLING FREQUENCY

Type 1 Heat insulating

3 cubes for compressive strength + density 1 bar for linear change

1 per batch of 5 tonnes or less

Type 2 Erosion resistant/ heat-insulating

3 cubes for compressive strength + density 1 bar for linear change 2 plates for erosion


Type 3 Extreme duty erosion resistant

3 cubes for compressive strength + density 2 plates for erosion


Samples are defined as follows:

− Cold Crushing cubes 50 x 50 x 50mm

− Permanent Linear Change bars 230 x 50 x 50mm

− Erosion plates 114 x 114 x 25mm

All test specimens shall be prepared without metallic fibres.

Certification of pre-shipment test results shall be forwarded to the Owner/Inspector for review prior to any lining application being performed.

Sample test results shall meet the values specified in Table 1.


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If test results for cold crushing and erosion fall within 10% of the specified values, or fall below the minimum specified values (maximum value for erosion and PLC), then either re-testing will be required or the relevant batch shall be rejected.

11.2 Operator qualification

Unless otherwise specified, the Installer shall qualify his personnel as follows:

11.2.1 Prequalification for gunite application

For each material to be used, each nozzleman shall gun a test panel measuring at least 600 x 600mm x proposed lining thickness which shall be placed in the overhead position at an angle of 45°.

This panel shall be constructed of steel, wood or plastic and have removal sides and backing plate – the anchors shall be bolted to the panel to enable removal of the castable after the test. An area within the panel should be left free of anchors enabling a section of the panel to be cut away.

After gunite application, the panel should be allowed to air-cure for 24 hours.

The refractory will then be hammer tested, removed from the panel and cut into four sections to be examined for voids, dry material, laminations and the dispersal of fibres (when used).

A section measuring at least 250 x 250mm will then be cut from one of these sections and sent to the laboratory for testing (number and type as per para 11.3.1).

Satisfactory test results as per the values of Table 1 will serve to qualify the nozzleman and the mixing and installation procedures.

11.2.2 Prequalification for vibrocast / freeflow application

A mock-up simulating the most difficult shape of the actual installation shall be made using two or more externally mounted mechanical vibrators and the intended type of forms.

As a minimum, the mock-up test-piece shall be an elbow with an internal diameter of at least 900mm and shall have at least two simulated nozzles of 50mm diameter welded to the shell which protrude the lining thickness, and one flush with the lining thickness. Do not use vibrators for Freeflow castables.


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The test should demonstrate that the vibrators are capable of ‘moving’ the castable with the specified water content and that the forms do not move, float or collapse, that they are readily removable and provide a suitable surface finish.

During the mock-up, a sample box measuring at least 250 x 250 x 100mm will be placed on the test-piece and vibrated in a similar fashion.

After leaving the test piece for 24 hours, the forms shall be removed and the vibrocast hammer tested and visually examined for surface defects, voids or dry in-fill areas.

The test sample shall be sent to the laboratory and tested (number and type as per § 11.3.2).

11.2.3 Prequalification for hand-packing into hexmesh

Each applicator shall hand-pack a test panel of hexmesh, 300 x 300 x specified thickness, which shall be attached to a removable backing of steel, wood or plastic and placed in the vertical position.

At the same time, each applicator shall prepare two erosion plates for laboratory testing.

After 24 hour air curing, the panel shall be removed from its backing and examined for voids and dry in-fill.

Satisfactory visual examination and test results will serve to qualify the applicator and the mixing procedures.

11.3 As-installed samples

11.3.1 Gunite application

One panel measuring a minimum of 400 x 400 x 100mm shall be gunned in the vertical position per nozzleman per shift.

Panel shall be constructed of steel, wood or plastic or, as an alternative, a wire mesh basket made of approximately 13mm mesh openings can be placed on the vessel wall during actual application, filled and then immediately removed.

All loose refractory or rebound entrapment where the basket was placed shall be removed.


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The following samples shall be cut from the above block for testing:

− 3 no Cold Crushing cubes 50 x 50 x 50mm (Types 1,2 + 3)

− 1 no Permanent Linear Change bars 230 x 50 x 50mm (Types 1 + 2 )

− 2 no Erosion plates 114 x 114 x 25mm (Types 2 + 3)

11.3.2 Vibrocast & freeflow appications

For each section or spool piece to be lined, a sample box measuring at least 250 x 250 x 100mm will be placed on the equipment being lined and vibrated in a similar fashion.

From this sample the following samples shall be cut for testing:

− 3 no Cold Crushing cubes 50 x 50 x 50mm (Types 2 + 3)

− 1 no Permanent Linear Change bars 230 x 50 x 50mm (Type 2)

− 2 no Erosion plates 114 x 114 x 25mm (Types 2 + 3)

11.3.3 Hand-packing applications (For type 3 materials)

A set of samples shall be prepared per shift/mixing crew and shall be cast directly in to the test sample moulds.

− 3 no Cold Crushing cubes 50 x 50 x 50mm

− 2 no Erosion plates 114 x 114 x 25mm

Hand casting of type 1 or 2 materials will necessitate a sample box as per § 11.3.2 and samples as per § 11.3.1.

11.3.4 The quality of as-installed samples shall not exceed the Table 1 specified values by more than 10% BELOW the values of density & compression or 10 % above the value of erosion – no deviation is permitted for linear change.

In the event of disagreement over the quality of the installed lining, additional samples may be sent for testing or core samples shall be taken as § 11.3.7.

11.3.5 The testing of the as-installed samples shall be at the discretion of the Inspector but as a minimum at least one set of samples per piece of equipment shall be tested. Results of as-installed samples must be submitted and approved by the Client prior to shipment of the lined equipment.


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11.3.6 Records shall be kept by the Applicator to identify the operative, the mixing data and ambient conditions, the location and type of the as-installed samples.

11.3.7 To resolve questions concerning the as-installed quality, cylindrical core samples measuring 75mm diameter shall be taken from the lining.

These core samples shall then be cut to give parallel faces to obtain cubes of 50mm diameter and shall be tested for compressive strength.

11.4 Testing of samples

All refractory testing will be performed in accordance to the standards used by the manufacturer for the original pre-shipment testing (ASTM or ISO).

11.4.1 Drying and firing

Remove the specimens from the moulds (or cut from blocks as necessary) after 24 hours and dry for 18 hours at 105°C.

Heat the specimens as per ASTM C865 to 815°C and hold for 5 hours.

Cool at a maximum rate of 150°C per hour.

11.4.2 Compressive strength testing

Testing shall conform to ASTM C133 and the following:

− Loading head of test machine shall have a spherical/floating loading head

− Cardboard shims or similar (75 x 75mm x 1.5-3mm thick) shall be placed between head of test machine and the specimens – use new shims for each test

11.4.3 Permanent linear change

At room temperature, measure the length (230mm direction) of bars after having dried to 105°C – take five measurements - the four corners and centre points and report as an average of five.

After heating to 815°C, re-perform the above measurements (at room temperature) and report the percentage average linear change.

11.4.4 Erosion tests

Testing shall conform to ASTM C704.


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− New silicon carbide grit to be used for each test.

12 Inspection / Repairs

12.1 Hammer testing of the lining shall take place after a minimum of 24 hours air curing and/or when the refractory material has taken its final set.

Further hammer testing shall also take place after heat-curing (if applicable).

12.2 A hammer weighing no more than 300 grammes should be struck on the surface of the lining at 300-500mm intervals – this interval should be closer for thin-wall erosion resistant linings using type 3A/3B materials, particularly in hexmesh anchorage.

12.3 After heat-cure, visually inspect the lining. On gunite or vibrocast/Freeflow linings, surface cracking of up to 3mm and full-depth cracks back to shell of up to 1.5mm, can be considered acceptable.

12.4 Cracks exceeding the parameters of § 12.3 above, loose/hollow sounding areas and soft or dry fill areas, should be removed back to the shell exposing a minimum of three anchors. The edges of the surrounding sound refractory shall be prepared as per § 9.2.9.

All repairs should be made using the original refractory material and installation technique.

12.5 Cast applications performed using internal formwork may show surface voids or air bubbles – this is due to air expulsion during the casting.

The following dimensions of surface voids are considered acceptable:

− Up to 12mm wide and 6mm deep

− Up to 20mm wide and 3mm deep

12.6 Voids in excess of the above tolerances, shall be cleaned out or drilled with a masonry bit and in-filled with type 3a or 3b material, allowed to air-cure and then be ground flush.

Voids in excess of 70% of the lining thickness, shall be repaired as per § 12.4 above.

12.7 Any step joints against the gas flow between refractory applications, spool piece sections, change of direction etc. in excess of 3mm shall be ground flush.


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12.8 Thickness tolerances shall be as follows:

− At pipe/vessel ends

• Gunned linings = -0mm / +3mm

• Cast (vibro/freeflow) linings = -3mm / +3mm

− Within pipe/vessel sections

• Gunned linings = -0mm / +12mm

• Cast (vibro/freeflow) linings = -3mm / +6mm for straight sections

• Cast (vibro/freeflow) linings = -10mm / +10mm for curved sections

12.9 For type 3A/3B materials installed in hexmesh, the acceptance criteria shall be as follows:

12.9.1 Lining thickness shall be –0.0 to +1.0mm.

Grinding will be required if the lining protrudes the hexmesh by more than 1.0mm.

If lining is more than 1.0mm below the level of the hexmesh, that hexagon and all adjacent hexagons to be removed and the lining replaced.

12.9.2 Gaps between the hexmesh and the refractory less than 0.5mm which are not full depth where separation has occurred (due to dragging or slumping) shall be considered acceptable. Gaps between 0.5 – 1.5mm will be repaired by using a cosmetic infill of sieved type 3A/3B material.

12.9.3 Gaps which are full depth and/or greater than 1.5mm in width or hexagons which vibrate or sound hollow as a result of hammer testing, shall be completely replaced as per § 12.9.1.

12.10 If un-satisfactory as-installed test results are obtained and/or subsequent core samples also prove un-satisfactory, the area or section lined represented by the sample identified in the sample location sheet, shall be removed.

For this reason, it is suggested that the installing contractor keeps a second series of samples.

12.11 When specified or required by the Owner, in addition to or as an alternative to the requirements of § 12.10 above, radiographs of the installed lining may be necessary and a detailed procedure of such should be submitted to the Owner for approval.


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13 Summary of Approvals / Documentation

13.1 To be provided and/or defined by the Owner/Purchaser

− refractory installation specification

− scope of supply

− drawings and necessary documentation

− type and material grade of anchorage

− type and material grade of refractory products

13.2 To be provided by the Fabricator / Installer

See paragraph 2.4.


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ANNEX 1

VEE ANCHOR FOR GUNNED/CAST MONOLITHIC LININGS

Shell

Surface of refractory

C = Diameter

A

B

60°

X

25mm

T

5mm

25m13mm radius

9mm radius

T = Total lining thickness

T A B C 51-80mm

150 mm 150 mm 6 mm

81–140mm 225 mm 225mm 8 mm More than 140mm

To be specified

Shell

Weld all around external radius of anchor stopping weld 5mm from end

Branches of vees to be randomly orientated

Plastic caps

5

X = 20-25% of T


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ANNEX 2

VEE ANCHOR FOR GUNNED/CAST MONOLITHIC LININGS

45°

X

20mm

T

Surface of refractory

T = Total lining thickness

T A B C Less than 50mm

75mm 75mm 5mm

51 - 80mm

150 mm 150 mm 6mm

81 - 140 225 mm 225 mm 8mm More than 140mm

To be specified

C – Diameter See table below

3 - 5mm x 20mm

Shell

A

B

Branches of vees to be randomly orientated

X = 20-25% of T


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ANNEX 3

TWO-PIECE WYE ANCHOR FOR GUNNED/CAST DUAL-LAYER

10mm diameter

6-8mm diameter(depending on thickness of hot-face lining)

A

3 mm min x 360°

Weld anchor or S-bar to nut both sides Anchor pitch and spacing will be dependent on thickness and type of refractory - to be specified.

Insulating lining

Hot-face lining

10 < A < 20

DUAL-LAYER SYSTEM USING S-BARS

Formwork

1. Cast back-up lining 2. Weld S-bars and install hot-facelining


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ANNEX 4

DUAL-LAYER LINING STUD AND PLATE-HEAD SYSTEM

Plate-head: 50 x 50 x 6mm

Stud: 10mm diameter

Weld 4mm min fillet at all points of contact of plate-head to hexmesh.

Erosion resistant lining

Insulating lining

200mm

200m

m

Tack-weld plate-head to stud


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B

A

L

E W

E L A B W 19 67 50 80 13 25 102 60 115 19 50 102 85 120 19 75 102 85 120 19 100 102 85 120 19

Dimensions in millimetresS bar layout type 1

Detail

FLOW

B

A

S bar layout type 2

E L A B W 19 67 65 65 13 25 102 80 80 19 50 102 90 90 19 75 102 90 90 19 100 102 90 90 19

ANNEX 5

S BAR ANCHORAGE

1. Dimensions for A and B are recommendations and may requiring increasing for linings in excess of 50mm thick and decreasing when used on external surfaces of small diameter piping – submit alternatives for Owner approval.


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ANNEX 6

HEXMESH WELD PATTERN

Figure 6: Details of hexmesh weld pattern and attachment to edge-bars. NOTE : Hexmesh panel welds to be 3mm (leg) x 20 mm long

Typical details of attachment of panel ends to edge-bar Fillet 3mm (leg) x 15mm both sides OR Fillet 3mm (leg) x full depth + fillet 3 mm (leg) x 15mm OR Fillet 3mm (leg) x full depth both sides

Fillet 3mm (leg) x full depth both sides (typical) OR to base plate

Fillet 3mm (leg) x 15mm min to base plate OR full-depth of tag-end to bar

Weld pattern for extreme service (reactor, reactor transfer lines, cyclones etc.) - weld every hexagon.

Weld pattern for normal service - weld every hexagon, every other row.

Edge-bar: 5mm thk x 19/25mm

FLOW


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ANNEX 7

HEXMESH WELD PATTERN

Figure 7e – TOTALFINAELF design off-set lance hexmesh

Alternative weld patterns for extreme service (reactor, reactor transfer lines, cyclones etc.) - weld every hexagon. NOTE : Hexmesh panel welds to be 3mm (leg) x 20 mm longFigure 7a Figure 7b

Alternative weld patterns for normal service.

Figure 7c Figure 7d

5.5mm

A B

6mm

When B=25, A=13.5mm When B=19, A=7.5mm

FLOW

FLOW


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ANNEX 8

HEXMESH PARALLEL JOINT DETAILS

Joint

Parallel circumferential butt joint

Joint

Figure 8: Details of hexmesh panel joints on flat or cylindrical surfaces.

0mm min. - 10mm max. gap

Weld all panel ends to base plate

Parallel vertical butt joint

15mm min. - 35mm max. gap


Parallel vertical off-set butt joint

Parallel circumferential off-set butt joint

Weld brigding piece if hexagon is bigger than 1,5 times original size


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ANNEX 9

HEXMESH RE-SIZING OF SMALL HEXAGONS

Hexagons too small

Remove strips

Weld bridging pieces

3mm x full depth

Method 1

1A

1B

1C

2A

2C

2B

Method 2

600mm

300mm 300mm

3/4mm slots

Detail of expansion cuts in edge-bars (when specified)


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ANNEX 10

HEXMESH CONICAL JOINT DETAILS


0 mm min, - 10mm max Ensure there is sufficient room to install refractory

Weld bridging piece if hexagon is bigger than 1.5 times original size

Detail of hexmesh attached directly to plate

Detail of hexmesh joints suspended on plate-heads

2mm thk binding strip

4mm x 15mm

3mm x full depth


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ANNEX 11

HEXMESH JOINTS – CORRECTIVE DETAILS

Remove strip and install bridging pieces

Install bridging pieces and weld full-depth both ends or one end and to base plate

Four thicknesses of hexmesh strip too close together – NOT acceptable

Remove tag-ends from one panel and weld remaining tag-ends to base plate

Hexes less than 0.5 times original size –too small – NOT acceptable

MIN ½ HEX MAX 1 ½ HEX

Tag-ends do not interlock – NOT acceptable


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ANNEX 12

FLEXMESH 10 min. 3mm

Figure 11a - typical weld pattern for flexmesh

3mm rod

16 / 19mm

Figure 11b - alternative typical weld pattern for flexmesh


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ANNEX 13

CORNER TABS

Variable angle corner tab Fixed corner tab

B B

A = 60mm unless otherwise specified B = 19 or 25mm (lining thickness) C = thickness of plate

B B

C

U-tab

Weld detail and spacing of tabs

A

10

10 10 A

A

A

10

10

10

A

A 4mm x 15mm alternate sides A 35 35


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ANNEX 14

MALE/FEMALE BACKING RING SYSTEM

Lining thickness

Truing rings to be fitted prior to lining installation

3mm maximum gap to be filled with high temperature mortar (Note 1) immediately prior to fit-up. Note 1 Acceptable manufacturers are:AP Green - Sairset T Ceramics - Blakite

Truing rings to be fitted prior to lining installation

Detail of closed refractory joint on piping (radiograph not required)

22 mm

25 mm


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ANNEX 15

JOINT DETAIL FOR RADIOGRAPHED WELD SEAMS

After examination of weld, in-fill joint with refractory using same technique of application as initial lining unless otherwise approved by the Owner

Initial lining

150-200mm

150-200mm


150-200mm 150-200mm

In horizontal or inclined position, casting of joint to be performed using internal forms and cast with Freeflow material via 75-100mm ID casting nozzle and then flanged


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ANNEX 16

HOT-WALL TO COLD-WALL TRANSITION

Bi-metallic weld

Three rows of hexagons maximum

60mm min

Type 2a/2b

6mm thk 304h ring installed in sections. Weld all ends of hexmesh full-depth to ring.

Type 3 material



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ANNEX 17

TABLE 1 – REFRACTORY MATERIAL PROPERTIES TYPES 1 + 2A

Type 1 Heat-insulating For insulating purposes – typically reactor/regenerator main walls, third stage separator vessels etc

MANUFACTURERS AND Gouda Vuurvast - PRODUCT NAMES Plibrico - Pliline LW-22/22G Thermal Ceramics - Kaolite 2500 HS Resco - RS-9, RS-3E, RS-7 Max service temp (°C) 1100 Erosion loss (cm3) - Bulk density (kg/m3 @ 110°C) 1050-1550 Permanent Linear Change (%) (note 1) < -0.3 Bulk density (kg/m3 @ 815°C) 970-1450 Thermal Conductivity (Wm°C) @815°C < 0.38 Crushing Strength (kg/cm2 @ 815°C) > 38 Return Thermal Expansion (note 2) 2.9-4.4

Type 2A-C Medium erosion resistant /heat-insulating Typically for reactor/regenerator catalyst transfer lines – good resistance to erosion – typically applied by vibrocast

MANUFACTURERS AND Gouda Vuurvast - PRODUCT NAMES Plibrico - Pliline MW-27V Thermal Ceramics - Kaotuff CV Resco - RS-17EC Max service temp (°C) 1100 Erosion loss (cm3) < 10 Bulk density (kg/m3 @ 110°C) 2120-2250 Permanent Linear Change (%)(note 1) < -0.3 Bulk density (kg/m3 @ 815°C) 2050-2200 Thermal Conductivity (Wm°C) @815°C < 1.02 Crushing Strength (kg/cm2 @ 815°C) > 560 Return Thermal Expansion (note 2) 3.5-5.2

Type 2A-G Medium erosion resistant /heat-insulating Typically for reactor/regenerator catalyst transfer lines – good resistance to erosion – typically applied by pneumatic gunite

MANUFACTURERS AND Gouda Vuurvast - PRODUCT NAMES Plibrico - Pliline MW-27G Thermal Ceramics - Kaotuff G Resco - RS-17EG Max service temp (°C) 1100 Erosion loss (cm3) < 14 Bulk density (kg/m3 @ 110°C) 2220-2400 Permanent Linear Change (%)(note 1) < -0.3 Bulk density (kg/m3 @ 815°C) 2100-2400 Thermal Conductivity (Wm°C) @815°C < 1.02 Crushing Strength (kg/cm2 @ 815°C) > 520 Return Thermal Expansion (note 2) 3.5-5.2


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Type 2A-F Medium erosion resistant /heat-insulating Typically for reactor/regenerator catalyst transfer lines – good resistance to erosion – typically applied by freeflow casting

MANUFACTURERS AND Gouda Vuurvast - PRODUCT NAMES Plibrico - Pliline MW-27S - Resco - RS-17E SF Max service temp (°C) 1100 Erosion loss (cm3) < 12 Bulk density (kg/m3 @ 110°C) 2150-2250 Permanent Linear Change (%)(note 1) < -0.3 Bulk density (kg/m3 @ 815°C) 2050-2200 Thermal Conductivity (Wm°C) @815°C < 1.02 Crushing Strength (kg/cm2 @ 815°C) > 620 Return Thermal Expansion (note 2) 3.5-5.2


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TABLE 1 – REFRACTORY MATERIAL PROPERTIES TYPE 2B

Type 2B-C Less erosion resistant/more heat-insulating Typically for reactor/regenerator catalyst transfer lines – some resistance to erosion – typically applied by vibrocast

MANUFACTURERS AND Gouda Vuurvast - PRODUCT NAMES Plibrico - Pliline LW-26 VLI Resco - RS-17EMC Max service temp (°C) 1100 Erosion loss (cm3) < 18 Bulk density (kg/m3 @ 110°C) 1840-1930 Permanent Linear Change (%)(note 1) < -0.3 Bulk density (kg/m3 @ 815°C) 1750-1850 Thermal Conductivity (Wm°C) @815°C < 0.72 Crushing Strength (kg/cm2 @ 815°C) > 350 Return Thermal Expansion (note 2) 3.5-5.2

Type 2B-G Less erosion resistant/more heat-insulating Typically for reactor/regenerator catalyst transfer lines – some resistance to erosion – typically applied by gunite

MANUFACTURERS AND Gouda Vuurvast - PRODUCT NAMES Plibrico - Pliline MW-26 GLI Resco - RS-17EMG Max service temp (°C) 1100 Erosion loss (cm3) < 20 Bulk density (kg/m3 @ 110°C) 1840-1930 Permanent Linear Change (%)(note 1) < -0.3 Bulk density (kg/m3 @ 815°C) 1750-1850 Thermal Conductivity (Wm°C) @815°C < 0.72 Crushing Strength (kg/cm2 @ 815°C) > 220 Return Thermal Expansion (note 2) 3.5-5.2

Type 2B-F Less erosion resistant/more heat-insulating Typically for reactor/regenerator catalyst transfer lines – some resistance to erosion – typically applied by freeflow casting

MANUFACTURERS AND Gouda Vuurvast - PRODUCT NAMES Plibrico - Pliline MW-26 SLI Resco - RS-17EM SF Max service temp (°C) 1100 Erosion loss (cm3) < 18 Bulk density (kg/m3 @ 110°C) 1840-1930 Permanent Linear Change (%)(note 1) < -0.3 Bulk density (kg/m3 @ 815°C) 1750-1850 Thermal Conductivity (Wm°C) @815°C < 0.72 Crushing Strength (kg/cm2 @ 815°C) > 340 Return Thermal Expansion (note 2) 3.5-5.2


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TABLE 1 – REFRACTORY MATERIAL PROPERTIES TYPES 3A+3B

Type 3A Extreme erosion resistant Typically for hotwall reactor/regenerator catalyst transfer lines, cyclones, risers etc – typically applied by hand-packing

MANUFACTURERS AND Gouda Vuurvast - Curas 90PF PRODUCT NAMES Plibrico - Pliline C90 PC Thermal Ceramics - Kaocrete HPM 90TR Resco - AA-22S Max service temp (°C) 1100 Erosion loss (cm3) < 5 Bulk density (kg/m3 @ 110°C) > 2600 Permanent Linear Change (%)(note 1) < -0.3 Bulk density (kg/m3 @ 815°C) > 2600 Thermal Conductivity (Wm°C) @815°C - Crushing Strength (kg/cm2 @ 815°C) > 650 Return Thermal Expansion (note 2) 4.3-6.4

Type 3B Ultra erosion resistant Typically for hotwall reactor/regenerator catalyst transfer lines, cyclones, risers etc – typically applied by hand-packing

MANUFACTURERS AND Gouda Vuurvast - PRODUCT NAMES Plibrico - Pliline B 85 MP Dramicom - Actchem Resco - R-MAX MP Max service temp (°C) 1100 Erosion loss (cm3) < 3 Bulk density (kg/m3 @ 110°C) > 2600 Permanent Linear Change (%)(note 1) < -0.3 Bulk density (kg/m3 @ 815°C) > 2600 Thermal Conductivity (Wm°C) @815°C - Crushing Strength (kg/cm2 @ 815°C) > 1100 Return Thermal Expansion (note 2) 4.3-6.4

NOTES:

1. Expressed as % change between 105 and 815°C as per § 11.4.3.

2. Expressed in millimeters per linear metre at between 540-815°C –(RTE is normally greater than the PLC).

3. All testing performed in accordance with relevant ASTM standards.

4. Type 3B materials can be used as a substitute for type 3A – note that 3A materials CANNOT substitute 3B materials.


JERES-N-150 Rev. 0




Page 53 of 53

ANNEX 18

This document was written from the following ex-TOTAL, ex-FINA and ex-ELF specifications:

− TOTAL : B 230 - Revision 1 - April 1989

"REVETEMENTS INTERNES ISOLANTS ANTI-EROSION DES CAPACITES ET CONDUITES DANS LES UNITES DE CRAQUAGE CATALYTIQUE"

− ELF : SGI 0005 ISL - Revision A - November 1995

"SHAPED AND UNSHAPED ABRASION RESISTANT REFRACTORIES"

Documents

JERES-N-150 Erosion Resistant Refractory Lining-FCC Piping